Composite structure assembly having an interconnected layered core

Abstract

A composite structure assembly and method of forming a composite structure assembly is provided. The composite structure assembly includes a composite core including a first cell layer having a plurality of first cells and a second cell layer having a plurality of second cells. The first cell layer is adjacent to the second cell layer. The plurality of first cells are fluidly interconnected with the plurality of second cells.

What is claimed is: 
     
       1. A composite structure assembly, comprising:
 a composite core including a first cell layer having a plurality of first cells and a second cell layer having a plurality of second cells, wherein the first cell layer is adjacent to the second cell layer, and wherein the plurality of first cells are fluidly interconnected with the plurality of second cells; and 
 a plurality of connecting beams that connect the first cell layer to the second cell layer. 
 
     
     
       2. The composite structure assembly of  claim 1 , wherein each of the plurality of first cells is in fluid communication with at least two of the plurality of second cells, and wherein each of the plurality of second cells is in fluid communication with at least two of the plurality of first cells. 
     
     
       3. The composite structure assembly of  claim 1 , wherein the first cell layer is offset with respect to the second cell layer. 
     
     
       4. The composite structure assembly of  claim 3 , wherein the first cell layer is rotationally offset with respect to the second cell layer. 
     
     
       5. The composite structure assembly of  claim 3 , wherein the first cell layer is linearly offset with respect to the second cell layer. 
     
     
       6. The composite structure assembly of  claim 3 , wherein the first cell layer is offset with respect to the second cell layer through a difference in one of both of shape or size between the plurality of first cells and the plurality of second cells. 
     
     
       7. The composite structure assembly of  claim 1 , wherein the first cell layer comprises a plurality of first cross members that define the plurality of first cells, wherein the first cross members are parallel to one another. 
     
     
       8. The composite structure assembly of  claim 7 , wherein the second cell layer comprises a plurality of second cross members that define the plurality of second cells. 
     
     
       9. The composite structure assembly of  claim 8 , wherein the plurality of first cross members are perpendicular to the plurality of second cross members. 
     
     
       10. The composite structure assembly of  claim 8 , wherein the plurality of first cross members are linearly shifted in relation to the plurality of second cross members. 
     
     
       11. The composite structure assembly of  claim 8 , wherein each of the plurality of first cross members differs in one or both of size or shape from each of the plurality of second cross members. 
     
     
       12. The composite structure assembly of  claim 1 , wherein the plurality of first cells are staggered in relation to the plurality of second cells to provide increased structural support for a skin. 
     
     
       13. The composite structure assembly of  claim 1 , further comprising at least one skin secured to the composite core. 
     
     
       14. A method of forming a composite structure assembly, the method comprising:
 forming a first cell layer having a plurality of first cells; 
 forming a second cell layer having a plurality of second cells; and 
 securing the first cell layer to the second cell layer to form a composite core, wherein the first cell layer is adjacent to the second cell layer, wherein the securing fluidly interconnects the plurality of first cells with the plurality of second cells, and wherein the securing comprises connecting the first cell layer to the second layer with a plurality of connecting beams. 
 
     
     
       15. The method of  claim 14 , wherein the securing comprises:
 fluidly coupling each of the plurality of first cells with at least two of the plurality of second cells; and 
 fluidly coupling each of the plurality of second cells with at least two of the plurality of first cells. 
 
     
     
       16. The method of  claim 14 , wherein the securing comprises offsetting the first cell layer with respect to the second cell layer. 
     
     
       17. The method of  claim 16 , wherein the offsetting comprises one or more of: rotationally offsetting the first cell layer with respect to the second cell layer, linearly offsetting the first cell layer with respect to the second cell layer, or offsetting the first cell layer with respect to the second cell layer through a difference in one of both of shape or size between the plurality of first cells and the plurality of second cells. 
     
     
       18. The method of  claim 14 , wherein the forming the first cell layer comprises providing a plurality of parallel first cross members that define the plurality of first cells, and wherein the forming the second cell layer comprises providing a plurality of parallel second cross members that define the plurality of second cells. 
     
     
       19. The method of  claim 18 , further comprising orientating the plurality of parallel first cross members to be perpendicular to the plurality of parallel second cross members. 
     
     
       20. The method of  claim 18 , further comprising linearly shifting the plurality of parallel first cross members in relation to the plurality of parallel second cross members. 
     
     
       21. The method of  claim 14 , wherein the securing comprises staggering the plurality of first cells in relation to the plurality of second cells to provide increased structural support for a skin. 
     
     
       22. The method of  claim 21 , further comprising securing at least one skin to the composite core.